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    WIRE EDM MACHINE OPERATION WIRE EDM MACHINE OPERATION TRAININGTRAINING LN1W / LN2W CONTROL (AQ400L, AQ600L, AD360L, All with FJ AWT) Part Number 6300015 January, 2012

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    (AQ400L, AQ600L, AD360L, All with FJ AWT) Copyright notice: The entire contents of this manual are protected under copyright laws. All rights reserved. Sodick Inc. 1605 N. Penny Lane Schaumburg, IL 60173 (847) 310-9000

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    Copyright January 2012 Sodick Inc. Table Of Contents DESCRIPTION OF THIS MANUAL vi Chapter 1 DESCRIPTION OF THE EDM PROCESS 1 GENERAL EDM FACTORS 2 WIRE DIAMETER AND WIRE GUIDES 2 WIRE TYPE 3 FLUSHING & NOZZLES 3 WATER RESISTIVITY 5 Chapter 2 MACHINE LAYO...

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    Copyright January 2012 Sodick Inc. VERTICAL ALIGNMENT MANUAL PROCEDURE 28 VERTICAL ALIGNMENT AUTOMATIC PROCEDURE 30 AWT ADJUSTMENTS ALIGNMENT PROCEDURE 31 MANUAL TILT OFFSET 33 AUTO TILT OFFSET 34 APPROACH FACE 35 EDGE FIND USING G80 36 EDGE FIND BY USING THE ST KEY 37 WIDTH CENTERING 38 CORNE...

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    Copyright January 2012 Sodick Inc. GLOBAL OFFSET CHANGING 63 FLAG7D: 63 Chapter 8 TAPER CUTTING INFORMATION 64 TAPER CUTTING CONSIDERATIONS 64 Maximum Taper Angle 64 HOW TO PROGRAM TAPER 65 Initializing Taper 66 TAPER PROGRAM EXAMPLE 67 TAPER SETTINGS IN THE CONTROL 68 Table to Limit 69 Table ...

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    Copyright January 2012 Sodick Inc. CORNER CONTROL 95 Chapter 10 UTY - Heart NC 96 Procedure for Loading DXF Files 96 USB FILE TRANSFER 96 LOADING DXF FILE 96 LOADING DXF FILE 97 CONFIGURE HEARTNC PARAMETERS, 101 NC PROGRAM CREATION OUTLINE 101 NC PROGRAM CREATION OUTLINE 102

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    Copyright January 2012 Sodick Inc. WEDM Training Course Outline Day 1:  Read Discuss Ch. 1 Description of the EDM Process.  Discuss EDM maintenance via powerpoint slides. Students can follow along in Ch. 3 of the manual.  At the machine, go over machine layout from Ch. 2 of the manu...

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    Copyright January 2012 Sodick Inc. DESCRIPTION OF THIS MANUALDESCRIPTION OF THIS MANUAL It is the intention of this course and manual to inform beginning and experienced operators of the techniques used in programming and operating Sodick Wire EDM systems. This manual is to be used in conjun...

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    Copyright January 2012 Sodick Inc.

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    Copyright January 2, 2012 1 Sodick Inc. Chapter 1Chapter 1 DESCRIPTION OF THE EDM PROCESSDESCRIPTION OF THE EDM PROCESS The first key concept that you must understand is the basic principle of the EDM process. One good analogy of what occurs in the EDM process is what is constantly happe...

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    Copyright January 2, 2012 2 Sodick Inc. GENERAL EDM FACTORSGENERAL EDM FACTORS WIRE DIAMETER AND WIRE GUIDES The operator should give thought to the diameter of the wire used to machine the part with. Generally speaking, the larger the diameter, the faster the machining speed will be. You m...

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    Copyright January 2, 2012 3 Sodick Inc. WIRE TYPE Sodick has developed the power supply to cut at very good speed and with very good accuracy with plain brass wire. Hard brass wire works best for all general cutting and taper cutting up to 10 degrees and for reliable AWT operation. Use h...

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    Copyright January 2, 2012 4 Sodick Inc. stable the EDM process will occur and wire breakage will decrease. During rough cutting, you usually want high flushing pressure (T84 code) to remove the particles. During skim cuts, you want low flushing pressure (T85 code) to avoid having the pressure ...

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    Copyright January 2, 2012 5 Sodick Inc. WATER RESISTIVITY The water resistivity affects the EDM process. The water is intended to be a dielectric, meaning that the water is an insulator to electricity. However, in real life this is impossible to achieve. There is a bottle containing deionizat...

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    Copyright January 2, 2012 6 Sodick Inc. Chapter 2Chapter 2 MACHINE LAYOUT DESCRIPTIONMACHINE LAYOUT DESCRIPTION Another key concept to understand is the basic makeup of the machine. Our intention first is to look at the machine from the operator’s viewpoint. Later, we will look at the mac...

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    Copyright January 2, 2012 7 Sodick Inc. Here is an introduction to many of the most important keys and switches on the control panel. These are important ones to be familiar with. To make it a little easier, we break them down into logical categories. CONTROL PANEL SWITCHESCONTROL PANEL SWI...

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    Copyright January 2, 2012 8 Sodick Inc. These switches are used to cut and automatically thread the wire. 5 [TENSION ON/OFF] switches Not Used. 6 [WIRE STOP/RUN] switches These switches are used to stop and start wire running. 7 [HIGH PRESSURE ON/OFF] switches These switches are used to turn h...

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    Copyright January 2, 2012 9 Sodick Inc. 12 [A0] to [A3] Switches These switches are used to execute program files which are stored in the NC unit. The relationship between the program file to be executed and the switches to be pressed is shown below. Using the Edit function you can customize ...

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    Copyright January 2, 2012 10 Sodick Inc. Use to start a program or after halting or when the control automatically stops the program’s operation maybe due to wire breakage, M00 or M01 this key allows you to continue from where the machine stopped. 18 [ST] switch This switch is used to cause...

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    Copyright January 2, 2012 11 Sodick Inc. MACHINE PANMACHINE PAN EL SWITCHESEL SWITCHES This panel is located near the flushing valves on the machine. Some of the keys on this panel are the same as the switch panel on the control. WIRE STOP/RUN – Allows you to manually turn on and off the...

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    Copyright January 2, 2012 12 Sodick Inc. ADDITIONAL ITEMS Hour Meter: Machine usage hours can bee seen on the Disply – Maint screen. At the bottom of this screen is the source on time, and also cutting time. Worktank Door UP and DOWN: The AD360L, AQ400L and AQ600L machines have a manual ...

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    Copyright January 2, 2012 13 Sodick Inc. UNDERSTANDING WORK COORDINATE SCREENSUNDERSTANDING WORK COORDINATE SCREENS Sodick allows you to assign up to 60 different program zero points. This could be helpful when you are machining multiple parts. However, most of the time you will only be inte...

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    Copyright January 2, 2012 14 Sodick Inc. Here is a list of all of the coordinate systems available: G CODE Display AT MACHINE G054 to G059 = work coordinates A054 to A059 G154 to G159 = work coordinates A154 to A159 G254 to G259 = work coordinates A254 to A259 G354 to G359 = work c...

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    Copyright January 2, 2012 15 Sodick Inc. Chapter 3Chapter 3 MAINTENANCEMAINTENANCE Sodick Wire EDMs are precision machine tools and should be treated as such. Preventative maintenance will eliminate unnecessary problems, downtime, and aggravation and should be performed on a regular basis r...

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    Copyright January 2, 2012 16 Sodick Inc. MAINTENANCE CHECKLISTMAINTENANCE CHECKLIST For additional information about maintenance items, please see the “Machine Tool” manual supplied with your machine. Daily Inspection Items Inspection Item Check To Perform Conductivity Piece Index every 5...

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    Copyright January 2, 2012 17 Sodick Inc. MAINTENANCE DESCRIPTIONS MAINTENANCE DESCRIPTIONS DI BOTTLE If the DI bottle needs to be recharged, 1. Turn off the circulation pump. 2. Disconnect the lines at the top of the bottle noting which one is “IN” and “OUT”. Put the disconnected ...

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    Copyright January 2, 2012 18 Sodick Inc. WATER FILTERS Machine Number of filters Filter type AD360L 2 SHF25E AQ400L, AQ600L 2 SHF25E AQ750L with LN1W 2 SHF25E AQ750L with LN33W 4 SHF25E Locate the filter pressure gauge on your machine. When the pressure gauge reaches the red zone, the filter...

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    Copyright January 2, 2012 19 Sodick Inc. CARBIDE POWER CONTACTS The carbide power feeders (conductivity piece) deliver the electricity to the wire thus charging it with current. They need to be indexed when the witness line (created by the wire) is about .005"-.010" deep (maximum) or...

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    Copyright January 2, 2012 20 Sodick Inc. WIRE GUIDES The upper and lower wire guides should be cleaned weekly, and checked for roundness monthly. Upper Guide: 1) Remove the nozzle assembly that carries the upper flush cup. 2) Use the guide tool to remove the guide and replace Lo...

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    Copyright January 2, 2012 21 Sodick Inc. unit is. Occasionally a piece of wire or a sliver slug will get lodged between the guides and the roller. That object must be removed to allow the roller to spin freely. It may be easier to work on this assembly if it is removed from the machine. To re...

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    Copyright January 2, 2012 22 Sodick Inc. WAY LUBRICATION AD325L, AG400L, AG600L: Grease is not required. WIRE GUIDE ASSEMBLY DRAWINGSWIRE GUIDE ASSEMBLY DRAWINGS Lower Guide Assembly – Nozzle Carbide Contact Guide Carbide Contact Screw Tool Tool

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    Copyright January 2, 2012 23 Sodick Inc. Upper Guide Assembly: AQ400L AQ600L AD360L Carbide Contact Screw Upper Guide Guide Tool Upper Nozzle Assembly

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    Copyright January 2, 2012 24 Sodick Inc. LOWER HEAD ALIGNMENT PROCEDURELOWER HEAD ALIGNMENT PROCEDURE Lower Head Alignment To check lower head alignment, use the round gauge ring (supplied with machine), a surface gauge and an indicator. Set the surface gauge on the ...

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    Copyright January 2, 2012 25 Sodick Inc. 1) Adjustment Screws 2) Locking Screws 3) Lower Arm 4) Gauge Ring Tool (from accessories kit)

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    Copyright January 2, 2012 26 Sodick Inc. Chapter 4Chapter 4 WIRE AND PART SETUP PROCEDURESWIRE AND PART SETUP PROCEDURES CHANGING WIRE SIZE SETTINGS ON THE MACHINECHANGING WIRE SIZE SETTINGS ON THE MACHINE When changing wire diameter, please confirm the...

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    Copyright January 2, 2012 27 Sodick Inc. SPOOL WEIGHT SETTING SPOOL WEIGHT SETTING Note: Below information doesn’t apply to models with jumbo spooler and AQ750L or AQ900L. When changing the weight of the wire spool, please adjust these settings. These settings change the rewind motor powe...

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    Copyright January 2, 2012 28 Sodick Inc. VERTICAL WIRE ALIGNMENTVERTICAL WIRE ALIGNMENT VERTICAL ALIGNMENT MANUAL PROCEDURE 1) Determine wire tension value for wire size to be used (pg24) 2) Blow-dry the AWT, Upper Guide Head Assembly, and Alignment Block. 3) Place the Alignment block on th...

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    Copyright January 2, 2012 29 Sodick Inc. NOTE: • It is not necessary to perform vertical alignment for each workpiece, but it must be performed in the following cases:  When it has not been performed for two or three days  After a collision with an obstacle  When a wire guide has ...

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    Copyright January 2, 2012 30 Sodick Inc. VERTICAL ALIGNMENT AUTOMATIC PROCEDURE 1) Confirm that the U and V axis are aligned within .010” already. 2) Clamp the block and indicate it straight and level on the front table 3) Position the wire to the right side and the upper head about .25...

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    Copyright January 2, 2012 31 Sodick Inc. AWT ADJUSTMENTS ALIGNMENT PROCEDUREAWT ADJUSTMENTS ALIGNMENT PROCEDURE The wire should be vertically aligned before performing this procedure. For the AWT to thread correctly, the U & V axis will need to offset to align the water jet with the lo...

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    Copyright January 2, 2012 32 Sodick Inc. Confirm on the “Setting”, “User2” screen that the AWT offsets have been logged correctly. You can also adjust the values directly here without using the “Manual”, “Prepare” screen discussed previously. If the holes to be threaded t...

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    Copyright January 2, 2012 33 Sodick Inc. MANUAL TILT OFFSETMANUAL TILT OFFSET 1. Move the wire near the first pickup location of a ground edge. 2. Set jog speed on remote to MFR = 2 3. Turn on “Wire Run” switch. 4. Press together the “ST” key and a jog key so the wire touches the ...

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    Copyright January 2, 2012 34 Sodick Inc. AUTOAUTO TILT OFFSETTILT OFFSET 1. Move the wire in front of the first pickup location. 2. Choose your “ST Direction” as the direction you need to move the wire in order to pick up the workpiece face. 3. Set your “Measur. Dimension”. This i...

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    Copyright January 2, 2012 35 Sodick Inc. APPROACH FACE APPROACH FACE 1. Choose “Manual”, “Codeless”, “Appr. Face” 2. Choose an Axis (X or Y) and direction (+ or -) you wish to pickup. 3. Enter your wire diameter = .010” (or your wire size). 4. Enter the inverted as 0. 5. Cl...

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    Copyright January 2, 2012 36 Sodick Inc. EDGE FIND USING G80 EDGE FIND USING G80 The G80 code will cause wire to travel into the edge of a workpiece, and stop with the wire flush to the edge. 1) Manually jog the wire close to the surface to edge find (within about 0.1”). 2) Choose “Manua...

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    Copyright January 2, 2012 37 Sodick Inc. EDGE FIND BY USING THE ST KEYEDGE FIND BY USING THE ST KEY Accuracy of the ST key is about .0002". The previous 2 methods for edge finding are by using the G80 code method. 1) Using the X and Y jog keys, position the wire close to the edge to be ...

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    Copyright January 2, 2012 38 Sodick Inc. WIDTH CENTERINGWIDTH CENTERING 1. Position the wire near to the center of the part width to be picked up. 2. Choose “Manual”, “Codeless”, “Width Center”. 3. Choose which direction to feed the wire towards the part. 4. Enter the feed amou...

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    Copyright January 2, 2012 39 Sodick Inc. CORNER FIND CORNER FIND 1. Choose “Manual”, “Codeless”, “Corner” 2. Click the corner position that you will be picking up. 3. Enter the feed amount as a rapid value for X and Y. They can be different amounts. 4. Enter coord. set after ...

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    Copyright January 2, 2012 40 Sodick Inc. HOLE CENTERINGHOLE CENTERING 1. Position the wire near the center of the hole to be picked up. 2. Choose “Manual”, “Codeless”, “Hole Center”. 3. Choose whether you want to pick up a “Hole” or “Gouge” which allows you to pick up an...

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    Copyright January 2, 2012 41 Sodick Inc. RARA NDOM 3 MANUALNDOM 3 MANUAL 1. Choose whether or not you want to move to the center of your workpiece after picking up the 3 measure points. If workpiece center is outside the machines travel, you need to set this to OFF. 2. Set your wire diamet...

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    Copyright January 2, 2012 42 Sodick Inc. RANDOM 3 AUTORANDOM 3 AUTO This feature is used for picking up inner diameters only. 1. Set your feed value. Enter a value that is smaller than your part diameter or just enter 0 if working with a small diameter. 2. Enter your 1st, 2nd, and 3rd co...

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    Copyright January 2, 2012 43 Sodick Inc. Chapter 5Chapter 5 EDM PROCESS PARAM ETERSEDM PROCESS PARAM ETERS Many factors called parameters control the way the EDM process occurs. What follows is an attempt to explain each of the parameters. For the beginner, remember that we are just introd...

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    Copyright January 2, 2012 44 Sodick Inc. ON Parameter Range: (roughing = 000-020, skimming = 000-331) “ON” stands for discharge ON time. This parameter controls the length of time that electricity is applied to the wire. The lower the number, the shorter the ON time will be. ON time is...

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    Copyright January 2, 2012 45 Sodick Inc. the actual power to the wire. A higher number increases the voltage available to the wire. While cutting, this parameter is usually not adjusted. The cutting condition file will set the value according to which pass is being made. MAO “MAO” sets ...

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    Copyright January 2, 2012 46 Sodick Inc. SV Parameter Range: (000-255) “SV” stands for servo voltage. This sets the gap voltage between the wire and the workpiece when cutting. Lowering this setting makes this gap smaller. Setting this to low makes the cut unstable because the parti...

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    Copyright January 2, 2012 47 Sodick Inc. “EPA” stands for “Easy Power Adjustment.” This setting allows you to adjust the aggressiveness of your rough pass ONLY without having to modify multiple parameters.

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    Copyright January 2, 2012 48 Sodick Inc. SF Parameter Range: (0000-9999) ”SF” stands for Servo Feed. This parameter sets the maximum feedrate the machine moves at when there is no load on the cut. By no load, we mean the wire hasn’t reached the workpiece and is not cutting yet. The SF w...

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    Copyright January 2, 2012 49 Sodick Inc. CHOOSING CUTTING CONDITIONSCHOOSING CUTTING CONDITIONS Cutting conditions and offsets can be found in the cutting condition manual, or they can be found in the machine’s library as described below. The condition search function automatically searche...

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    Copyright January 2, 2012 50 Sodick Inc. Leave set to Sodick Database Press Find Choose what surface finish you want on the part Press OK Make menu choice to describe your setup. Choose a precision level from the available choices

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    Copyright January 2, 2012 51 Sodick Inc. Results will be displayed. Press OK Machining conditions Offset Terms Other data Corner control data

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    Copyright January 2, 2012 52 Sodick Inc. UNDERSTANDING THE EDIT, CONDITION SCREENUNDERSTANDING THE EDIT, CONDITION SCREEN • Mach Fluid: Water: Standard database for Water machines. • Wire Dia.: Choose the wire diameter being used. • Wire Material: Choose Brass or Zinc-coated. • Wo...

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    Copyright January 2, 2012 53 Sodick Inc. SURFACE ROUGHNESS CONVERSION umRz Ra Uinch 15 90 8.0 50 5.0 32 3.8 23 2.5 15 2.0 12 Tips For Adjusting Cutting Conditions: During the rough cut, there may be instances in which you would like to adjust the cutting conditions. Be sure to choose the...

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    Copyright January 2, 2012 54 Sodick Inc. Wire Breakage Problem Example: Easy Power Adjustment: First try adjusting the EPA value by inputting -2. You are allowed to adjust this parameter from +2 to -4. If further adjustment is necessary, you can adjust one or more of the following paramete...

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    Copyright January 2, 2012 55 Sodick Inc. Speed Cutting Example: Easy Power Adjustment: First try adjusting the EPA value by inputting +1. You are allowed to adjust this parameter from +2 to -4. The rough-cut library settings are not MAXIMUM speed settings. They are designed to give good sp...

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    Copyright January 2, 2012 56 Sodick Inc. Chapter 6Chapter 6 DESCRIPTION OF PROGRAM M ING DESCRIPTION OF PROGRAM M ING CODESCODES This chapter will present most of the codes and words involved with programming. While there appears to be a great number of them, only a few are used on a regu...

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    Copyright January 2, 2012 57 Sodick Inc. RA: Specifies the amount of rotation about the G92 point of the program. Use G26 to turn it on. Think of the 3 o’clock position as 0 rotation. Rotating a program clockwise is a minus rotation and counter clockwise is a positive rotation. ...

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    Copyright January 2, 2012 58 Sodick Inc. LIST OF G CODESLIST OF G CODES G00 Rapid Motion G01 Straight Line Cutting Motion G02 Circular Cutting Motion - Clockwise (CW) G03 Circular Cutting Motion - Counterclockwise (CCW) G29 Reference Point Memory (for auto wire threader) G30 Ret...

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    Copyright January 2, 2012 59 Sodick Inc. M98 Jump to a Sub-Routine from the main program. M99 Return from a Sub-Routine to the main program. M199 End of Q-Routine (Use in place of M02 at the end of the Q routine). NC PROGRAM EXAMPLENC PROGRAM EXAMPLE The below program is an example to ma...

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    Copyright January, 2012 60 Sodick Inc. Chapter 7Chapter 7 WIRE OFFSET DESCRIPTIONWIRE OFFSET DESCRIPTION UNDERSTANDING OFFSETSUNDERSTANDING OFFSETS An offset tells the control how far to keep the wire centerline away from the programmed surface to be cut for any given pass. If making only ...

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    Copyright January, 2012 61 Sodick Inc. 3) When finished, you MUST cancel offset (using the G40 code during movement) Initializing Offset: To instate offset, you will be choosing from G41 (wire left) and G42 (wire right). You must be able to decide how the wire will be related to the workpiece d...

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    Copyright January, 2012 62 Sodick Inc. M02

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    Copyright January, 2012 63 Sodick Inc. GLOBAL OFFSET CHANGINGGLOBAL OFFSET CHANGING FLAG7D: Sometimes you may wish to add a clearance amount to all the offset values without having to add or subtract to each offset in the header. The code “FLAG7D” was designed to accomplish this. Before...

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    Copyright January, 2012 64 Sodick Inc. Chapter 8Chapter 8 TAPER CUTTING INFORM ATIONTAPER CUTTING INFORM ATION Now we will discuss taper cutting. We will limit our discussions about taper cutting to machining die clearance angles. There are other applications for taper cutting, but we feel ...

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    Copyright January, 2012 65 Sodick Inc. thickness, use the following calculation (angle must never exceed 15° with standard guides). Max Angle = TAN –1 [U axis travel per side / [part thickness + .800]] HOW TO PROGRAM TAPERHOW TO PROGRAM TAPER Now that you know the theory of taper cuttin...

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    Copyright January, 2012 66 Sodick Inc. Initializing Taper First let’s discuss initializing taper correctly. To initialize the taper cutting mode, you must look in the direction the wire will be moving during the cut (rotate print if necessary). Looking in this direction, ask yourself, “Whi...

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    Copyright January, 2012 67 Sodick Inc. TAPER PROGRAM TAPER PROGRAM EXAMPLEEXAMPLE TP1.0 (Table To Program, see next section) TN0.0 (Table To Next, see next section) N0000 G90 N0005 G54 N0010 G92 X.5 Y.2 N0015 G29 N0020 G41 H1 N0025 G51 A1.0 N0030 C1 N0035 T84 N0040 G0...

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    Copyright January, 2012 68 Sodick Inc. At the beginning of the program, the taper registers (TP – TN) receive their values. These values may be set by this method, or they may be set manually in the “Setting” screen (see figure 8-3). We prefer to set these values by the NC program like t...

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    Copyright January, 2012 69 Sodick Inc. “Table” here refers to the top surface of the pedestals. The figure below shows these relationships. A detailed description is on the following pages. Table to Limit Table To Limit is how far above the table the upper guide is when the head is at ...

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    Copyright January, 2012 70 Sodick Inc. Table to Program This is the distance from the tabletop to where you are holding size when taper cutting with G51 or G52. Here are four possible situations when the workpiece is mounted directly on the table. 1) Cutting with the top o...

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    Copyright January, 2012 71 Sodick Inc. TAPER SETTING EXAMPLESTAPER SETTING EXAMPLES Below examples help to explain the TP and TN value setting the operator needs to input. TP2.0TN0.0Die face up2.0”TP0.0TN2.0Die face down2.0”Simple taper programming scenarios: Table to ...

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    Copyright January, 2012 72 Sodick Inc. 0.75”0.1”0.25”Table to Program (TP): 0.35Table to Next (TN): 1.0Die face down with land and fixture example: Table to Program (TP): 0.65Table to Next (TN): 0.0Die face up with land example:0.75”0.1”

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    Copyright January, 2012 73 Sodick Inc. TAPER SETTINGS TAPER SETTINGS -- OPERATOR INPUTOPERATOR INPUT The following is what needs to be actually input by the operator for each taper cutting job. For complete parameter definitions see prior information on pages 8-7 thru 8-9. Taper Settings 1)...

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    Copyright January, 2012 74 Sodick Inc. NN OTES CONCERNING TAPER CUTTINGOTES CONCERNING TAPER CUTTING Calibrating T-Limit and T-Lower If you are not cutting accurate taper angles, it is possible that the constants called Table to Limit and Table to Lower in the Setting screen need to be chang...

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    Copyright January, 2012 75 Sodick Inc. AUTOMATIC CORNER ROUNDINGAUTOMATIC CORNER ROUNDING This feature was discussed during our descriptions of motion types (concept number three about G02 and G03 circular commands.) Here we will take it a little further. However, remember that these techniqu...

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    Copyright January, 2012 76 Sodick Inc.

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    Copyright January, 2012 77 Sodick Inc. Chapter 9Chapter 9 MISCELLANEOUS OPERATING AIDSMISCELLANEOUS OPERATING AIDS Operating aids are available to simplify programming and operating the machine. There are more capabilities you need to know about to make running the machine easier. The follo...

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    Copyright January, 2012 78 Sodick Inc. Q ROUTINE TECHNIQUESQ ROUTINE TECHNIQUES A Q routine is an operating aid, which allows the programmer to call up another separate nc program by filename from within a main-program. The Q’ed up program will be a separate file or program, sometimes ref...

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    Copyright January, 2012 79 Sodick Inc. MIRROR IMAGE AND AXIS EXCHANGEMIRROR IMAGE AND AXIS EXCHANGE There are several G codes involved with these features: G05 - Turn on X axis mirror image (X axis changes RED) G06 - Turn on Y axis mirror image (Y axis changes RED) G08 – Turn on X Y ax...

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    Copyright January, 2012 80 Sodick Inc. AXIS ROTATIONAXIS ROTATION The machine has 2 types of rotation, Figure rotation and coordinate rotation. FIGURE ROTATION: G26 / G27 codes. This function is used to rotate a programmed shape about the G92 position within a coordinate system. This funct...

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    Copyright January, 2012 81 Sodick Inc. COORDINATE ROTATION: G126 / G127 codes. This function is used to rotate the coordinate system. This is used in the Tilt Offset screen when you want to align the machines axis with the workpiece. This rotation stays active until the G127 code is used. ...

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    Copyright January, 2012 82 Sodick Inc. STRING FILESTRING FILE The string file is a converter or translation file. It lets the Sodick machine read and execute commands that it would not normally recognize. In the above example string file, the following changes have been made. END: This wo...

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    Copyright January, 2012 83 Sodick Inc. NOTES ABOUT DRY RUNNOTES ABOUT DRY RUN Always dry run the program when all axes are in the proper start point location. This is your last chance to catch any mistakes. Here is how Dry Run works in its three forms: Dry Run Modes • Dry Run 1: No sensor ...

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    Copyright January, 2012 84 Sodick Inc. FORMATTING FORMATTING EXTEXT ERNAL (USB)ERNAL (USB) MEMORYMEMORY 1) EXT Memory Format: Formatting of the USB drive is not required unless you wish to remove all data from the drive. 2) Ext Memory Folder: After formatting the USB drive, or if you re...

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    Copyright January, 2012 85 Sodick Inc. USB FOLDER STRUCTURE When you hit the “Ext Mem Folder” button, then the system creates the folders as seen above, on the USB stick. For the AQ and AD model machines the following folders are used as described. Backup: Parameter ...

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    Copyright January, 2012 86 Sodick Inc. DRAWING GRAPHICSDRAWING GRAPHICS The CNC Program must be loaded into Memory before this procedure is done. 16 Press the soft key next to EDIT, GRAPH 16 Set the graphic parameters the way you want. If you are taper cutting you must enter a value for T...

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    Copyright January, 2012 87 Sodick Inc. 16 If needed you can use the ENLARGE button to zoom up on a specific section of the drawing (see below picture). Note: If the program has a M00 or M01 at the end of the NC line, it may not appear in graphics. If on a line by themselves, they will appear...

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    Copyright January, 2012 88 Sodick Inc. MANUALLY ADJUSTING FLUSHINGMANUALLY ADJUSTING FLUSHING To set the flushing flow-rate there are 2 clear flow meters on the front of the machine with adjustment knobs. The flow meters have a scale measuring liters of flow per minute. Each meter has a floa...

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    Copyright January, 2012 89 Sodick Inc. SETTINGSETTING , USER 1, USER 1 SCREENSCREEN • SKIP - This manually turns on or off the block skip slash code in the program. This is the G11- G12 code if you want to program it. • NOMAN - When at 1 and an M02 is read, th...

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    Copyright January, 2012 90 Sodick Inc. • X-Y CHANGE - When ON, the X Axis becomes Y and the Y Axis becomes X: • MIRROR X - When ON, it flips the program in the X-axis. • MIRROR Y - When ON, it flips the program in the Y-axis. • MIRROR Z - Not Used • SCALE - Scale factor 1000 is full s...

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    Copyright January, 2012 91 Sodick Inc. SETTING, SETTING, USER 2 SCREEUSER 2 SCREE NN • AWT REFERENCE 0 = Wire break recovery turned off .If the wire breaks the machine stops. 1 = Wire-break rethread enabled. After threading the wire at the start hole it wil...

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    Copyright January, 2012 92 Sodick Inc. • AWT Z UP: This parameter is used to set the distance that the Z axis will raise if the wire breaks. If used, the Z axis raises after the wire breaks, but before the X and Y move back to the AWT rethread point. This may be used if the upper head has to ...

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    Copyright January, 2012 93 Sodick Inc. SETTING,SETTING, USERUSER 33 SCREENSCREEN • AIC Maximum R: This set the maximum radius that corner control will affect. Set this to .036” • Inching: This is the incremental jog feed distance. Set these to even values for...

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    Copyright January, 2012 94 Sodick Inc. SETTING, SETTING, USER USER 44 SCREENSCREEN • INIT INCH For Inch mode use ON. For metric mode use OFF. If you change units, you will be prompted to reboot the machine. You will need to do this reboot for the change to take...

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    Copyright January, 2012 95 Sodick Inc. CORNER CONTROLCORNER CONTROL Along with cutting conditions and offsets set to the header of the program, a “Q” command line will be added in the header. Normally the “QAIC” command line, seen above, will be set properly by the "COND SEARCH&...

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    Copyright January, 2012 96 Sodick Inc. CHAPT E R 10CHAPT E R 10 UT Y UT Y -- HE ART NCHE ART NC PP RO CE DURE F O R RO CE DURE F O R LL OA D I N G OA D I N G DXFDXF FF IL E SIL E S USB FILE TRANSFER At the external computer, copy the DXF file onto the Sodick Memory stick. Your DXF needs...

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    Copyright January, 2012 97 Sodick Inc. LOADING DXF FILE 1) Click UTY Key 2) Click File Key on the right.

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    Copyright January, 2012 98 Sodick Inc. 3) In the directory tree on the left, Pick where this file is originally stored EXT. Memory (memory stick) or SEIKAnet (network 3D_DATA folder) 4) Choose file and drag and drop into HeartNC

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    Copyright January, 2012 99 Sodick Inc. 5) Click Heart NC 6) Click File 7) Click Open 8) Choose DXF file (classa) and Click OK

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    Copyright January, 2012 100 Sodick Inc. DXF has been loaded into Heart NC. When you save it the extension will change to .ASC

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    Copyright January, 2012 101 Sodick Inc. CONFIGURE HEARTNC PARAMETERS, 1) Click “Set NC Dat Envt” 2) Adjust parameters as shown below. 3) Adjust “Connection allowance” as needed per your DXF file accuracy.  Adjustments made here save automatically

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    Copyright January, 2012 102 Sodick Inc. NC PROGRAM CREATION OUTLINE Preparation – Delete Unwanted Elements: Use “Delete” function and delete elements not used for the shape you want to cut. Delete any dimension lines or arrowheads that may be touching the shape. 1) Click Delete 2) Clic...

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    Copyright January, 2012 103 Sodick Inc. Preparation – Move Origin position to correct zero position: Decide where X Y zero position should be. A common place for this would be the center of the part or a corner of the part. 4) Click Status 5) Click Set Origin 6) Click on your drawing where X...

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    Copyright January, 2012 104 Sodick Inc. Start Point shows up on the screen to the left of the shape: NC program Creation – Punch Example 9) Click Wire Cut Defs - Punch

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    Copyright January, 2012 105 Sodick Inc. 10) Enter Punch parameters like shown below – then click OK. 11) Enter cutting condition parameters as shown below 12) Be sure to turn on “AIC” and “SFCC” buttons.

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    Copyright January, 2012 106 Sodick Inc. 13) Choose a surface finish and number of cuts as shown below. 14) Click OK 15) Follow the prompts at the bottom of the screen A) Click on the start point B) Click on the shape to cut (entire shape turns purple) C) Click where to le...

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    Copyright January, 2012 107 Sodick Inc. The toolpath is now completed. Next step is to post out the NC program 16) Click Gen NC Data 17) Type in a file name for this part classa 18) Click OK and the NC program transfers to the machines hard disk.

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    Copyright January, 2012 108 Sodick Inc. Load the program and prepare to cut the part. 19) Click Edit – File 20) Find the program we just made (classa) by sorting by name or date. 21) Double click on the file “classa” 22) NC program pops up in the Edit screen

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